Freescale Semiconductor, Inc. Design Reference Manual Document Number: DRM147 Rev. 0, 08/2014 Kinetis-M Three-Phase Power Meter Reference Design 1 Introduction This design reference manual describes a solution for a three-phase electronic power meter based on the MKM34Z128CLL5 microcontroller. This microcontroller is part of the Freescale Kinetis-M microcontroller family. The Kinetis-M microcontrollers are especially designed for electronic power meter applications. Thus the Kinetis-M family offers a high-performance analog front-end (24-bit AFE) combined with an embedded Programmable Gain Amplifier (PGA). In addition to high-performance analog peripherals such as an auxiliary 16-bit SAR ADC, these new devices integrate memories, input-output ports, digital blocks, and a variety of communication options. Moreover, the ARM® Cortex®-M0+ core, with support for 32-bit math, enables fast execution of metering algorithms. The commonly used three-phrase meter topology is based on the six or seven channels of sigma-delta (SD) ADC converters. Kinetis-M microcontrollers use different topology because of the 24-bit AFE (four channels of the 24-bit SD ADC) convertors and the 16-bit successive approximation (SAR) ADC converter with an input analog multiplexer. © 2014 Freescale Semiconductor, Inc. All rights reserved. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. A. B. C. Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MKM34Z128 microcontroller series . . . . . . . . . . . . . 3 Basic theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hardware design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Software design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Application set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 FreeMASTER visualization . . . . . . . . . . . . . . . . . . . 27 Accuracy and performance . . . . . . . . . . . . . . . . . . . . 30 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Board electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Introduction The main purpose of a three-phrase meter implementation on the KM3x devices is based on the signal’s dynamic range analysis. The current signal in metering is typically from 50mA to 120A, thus the current must be digitalized by a very precise and linear ADC with wide dynamic range, typically 24 bits. The SD method is an ideal solution to solve current dynamic range requirements. On the other hand, the voltage signal in metering is in the range of 80V to 280V. So the voltage dynamic range is approximately 60 times smaller than current dynamic range. The voltage requirements can be easily solved by a high-resolution SAR converter. The common reason for using six or seven independent ADC channels is for easier converter synchronization—that is, all channels are able to begin precisely at the defined time. The KM3x devices solve this problem by the peripheral called XBAR. The XBAR is an internal connection matrix among of the peripherals. Internal signals such as conversion complete from the SD converter can be used for starting SAR conversion. So the complete signal sampling process based on the combination of three or four SDs and one SAR with an input multiplexer is fully supported by the device’s hardware and only the conversion results must be read by the microcontroller core or by DMA. The three-phase power meter reference design is intended for the measurement and registration of active and reactive energies in three-phase four-wire networks. It is pre-certified according to the European EN50470-1, EN50470-3, classes B and C, and also to the IEC 62053-21 and IEC 62052-11 international standards for electronic meters of active energy classes 2 and 1. The integrated Switched-Mode Power Supply (SMPS) enables an efficient operation of the power meter electronics and provides enough power for optional modules, such as non-volatile memories (NVM) for data logging and firmware storage, a low-power magnetic field sensor for electronic tamper detection, and an RF communication module for AMR and remote monitoring. The power meter electronics are backed-up by a 3.6 V Li-SOCI2 battery when disconnected from the power mains. This battery activates the power meter whenever the user button is pressed or a tamper event occurs. The permanent triggers for tamper events include two tamper switches protecting the main and terminal covers. An additional optional tamper event is generated by a low-power 3-axis magnetometer sensor. The 3-axis magnetometer is useful to check for magnetic field changes which is important because current sensing is widely used with current transformers. This type of sensor guarantees the static magnetic field generated by the permanent magnet. The power meter reference design is prepared for use in real applications, as suggested by its implementation of a Human Machine Interface (HMI) and communication interfaces for remote data collecting. 1.1 Specification As already indicated, the Kinetis-M one-phase power meter reference design is ready for use in a real application. More precisely, its metrology portion has undergone thorough laboratory testing using the test equipment ELMA8303 [1]. Because of intensive testing, an accurate 24-bit AFE and 16-bit SAR ADC, and continual algorithm improvements, the three-phase power meter calculates active and reactive energies more accurately and over a higher dynamic range than required by common standards. All information, including accuracies, operating conditions, and optional features, are summarized in Table 1. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 2 Freescale Semiconductor, Inc. MKM34Z128 microcontroller series Table 1. Kinetis-M one-phase power meter specifications Description or Parameter Feature or Condition Type of meter Three-phase residential Type of measurement 4-Quadrant Metering algorithm Filter-based Precision (accuracy) IEC50470-3 class C, 0.5% (for active and reactive energy) Voltage range 90–265 VRMS Current range 0–120 A (5 A is nominal current, peak current is up to 154 A) Frequency range 47–53 Hz Meter constant (imp/kWh, imp/kVArh) 500, 1000, 2000, 5000 (default), 10000. Note, that pulse numbers 10000 are applicable only for low-current measurement. Functionality V, A, kW, kVAr, kVA, kWh (import/export), kVARh (lead/lag), Hz, time, date Voltage sensor Voltage divider Current sensor Current transformer (tested with different CT`s types) Energy output pulse interface Two red LEDs (active and reactive energy) Energy output pulse parameters: • Maximum frequency • On-Time • Jitter • 600 Hz • 20 ms (50% duty cycle for frequencies above 25 Hz) • ±10 is at constant power User interface LCD, one push-button, one user LED (red) Tamper detection Two hidden buttons (terminal cover and main cover) IEC1107 infrared interface 4800/8-N-1 FreeMASTER interface Optoisolated pulse output (optional) optocoupler (active or reactive energy) Isolated RS232 serial interface (optional) 19200/8-N-1 RF interface (optional) 2.4 GHz RF 1322x-LPN internal daughter card External NVMs (optional) • EEPROM AT24C32D, 32 KB Electronic tamper detection (optional) MAG3110, 3-axis digital magnetometer Internal battery 1/2AA, 3.6 V Lithium-Thionyl Chloride (Li-SOCI2) 1.2 Ah Power consumption @ 3.3V and 22°C: • Normal mode (powered from mains) • Standby mode (powered from battery) • Power-down mode (powered from battery) • 18.4 mA • 260 μA • 6.5 μA (both cover closed), 4.9 μA (covers opened) 2 MKM34Z128 microcontroller series The Freescale Kinetis-M microcontroller series is based on the 90-nm process technology. It has on-chip peripherals, and the computational performance and power capabilities to enable development of a low-cost and highly integrated power meter (see Figure 1). It is based on the 32-bit ARM Cortex-M0+ core Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 3 MKM34Z128 microcontroller series with CPU clock rates of up to 50 MHz. The measurement analog front-end is integrated on all devices; it includes a highly accurate 24-bit Sigma Delta ADC, PGA, high-precision internal 1.2 V voltage reference (VRef), phase shift compensation block, 16-bit SAR ADC, and a peripheral crossbar (XBAR). The XBAR module acts as a programmable switch matrix, allowing multiple simultaneous connections of internal and external signals. An accurate Independent Real-time Clock (IRTC), with passive and active tamper detection capabilities, is also available on all devices. Figure 1. Kinetis-M block diagram In addition to high-performance analog and digital blocks, the Kinetis-M microcontroller series has been designed with an emphasis on achieving the required software separation. It integrates hardware blocks supporting the distinct separation of the legally relevant software from other software functions. The hardware blocks controlling or checking the access attributes include: • ARM Cortex-M0+ Core • DMA Controller Module • Miscellaneous Control Module • Memory Protection Unit • Peripheral Bridge • General Purpose Input-Output Module The Kinetis-M devices remain first and foremost highly capable and fully programmable microcontrollers with application software driving the differentiation of the product. Nowadays, the necessary peripheral software drivers, metering algorithms, communication protocols, and a vast number of complementary software routines are available directly from semiconductor vendors or third parties. Because Kinetis-M microcontrollers integrate a high-performance analog front-end, communication peripherals, hardware blocks for software separation, and are capable of executing a variety of ARM Cortex-M0+ compatible Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 4 Freescale Semiconductor, Inc. Basic theory software, they are ideal components for development of residential, commercial, and light industrial electronic power meter applications. 3 Basic theory The critical task for a digital processing engine or a microcontroller within an electricity metering application is the accurate computation of the active energy, reactive energy, active power, reactive power, apparent power, RMS voltage, and RMS current. The active and reactive energies are sometimes referred to as the billing quantities. The remaining quantities are calculated for informative purposes, and they are referred to as non-billing. 3.1 Active energy The active energy represents the electrical energy produced, flowing or supplied by an electric circuit during a time interval. The active energy is measured in the unit of watt hours (Wh). The active energy in a typical one-phase power meter application is computed as an infinite integral of the unbiased instantaneous phase voltage u(t) and phase current i(t) waveforms. Wh = 3.2 ∞ 0 u ( t )i ( t ) dt Eqn. 1 Reactive energy The reactive energy is given by the integral, with respect to time, of the product of voltage and current and the sine of the phase angle between them. The reactive energy is measured in the unit of volt-ampere-reactive hours (VARh). The reactive energy in a typical one-phase power meter is computed as an infinite integral of the unbiased instantaneous shifted phase voltage u(t-90°) and phase current i(t) waveforms. VARh = 3.3 ∞ 0 u ( t – 90 ° )i ( t ) dt Eqn. 2 Active power The active power (P) is measured in watts (W) and is expressed as the product of the voltage and the in-phase component of the alternating current. In fact, the average power of any whole number of cycles is the same as the average power value of just one cycle. So, we can easily find the average power of a very long-duration periodic waveform simply by calculating the average value of one complete cycle with period T. 1 ∞ P = --- u ( t )i ( t ) dt T 0 3.4 Eqn. 3 Reactive power The reactive power (Q) is measured in units of volt-amperes-reactive (VAR) and is the product of the voltage and current and the sine of the phase angle between them. The reactive power is calculated in the same manner as active power, but in reactive power the voltage input waveform is 90 degrees shifted with respect to the current input waveform. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 5 Basic theory 1 ∞ Q = --- u ( t – 90 ° )i ( t ) dt T 0 3.5 Eqn. 4 RMS current and voltage The Root Mean Square (RMS) is a fundamental measurement of the magnitude of an alternating signal. In mathematics, the RMS is known as the standard deviation, which is a statistical measure of the magnitude of a varying quantity. The standard deviation measures only the alternating portion of the signal as opposed to the RMS value, which measures both the direct and alternating components. In electrical engineering, the RMS or effective value of a current is, by definition, such that the heating effect is the same for equal values of alternating or direct current. The basic equations for straightforward computation of the RMS current and RMS voltage from the signal function are the following: 2 1 T IRMS = URMS = 3.6 --- [ i ( t ) ] dt T 0 Eqn. 5 2 1 T --- [ u ( t ) ] dt T 0 Eqn. 6 Apparent power Total power in an AC circuit, both absorbed and dissipated, is referred to as total apparent power (S). The apparent power is measured in the units of volt-amperes (VA). For any general waveforms with higher harmonics, the apparent power is given by the product of the RMS phase current and RMS phase voltage. S = IRMS × URMS Eqn. 7 For sinusoidal waveforms with no higher harmonics, the apparent power can also be calculated using the power triangle method, as a vector sum of the active power (P) and reactive power (Q) components. S = 2 2 P +Q Eqn. 8 Due to better accuracy, we prefer to use Equation 7 to calculate the apparent power of any general waveforms with higher harmonics. In purely sinusoidal systems with no higher harmonics, both Equation 7 and Equation 8 will provide the same results. 3.7 Power factor The power factor of an AC electrical power system is defined as the ratio of the active power (P) flowing to the load, to the apparent power (S) in the circuit. It is a dimensionless number between -1 and 1. P cos ϕ = --S Eqn. 9 where angle ϕ is the phase angle between the current and voltage waveforms in the sinusoidal system. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 6 Freescale Semiconductor, Inc. Hardware design Circuits containing purely resistive heating elements (filament lamps, cooking stoves, and so forth) have a power factor of one. Circuits containing inductive or capacitive elements (electric motors, solenoid valves, lamp ballasts, and others) often have a power factor below one. The Kinetis-M one-phase power meter reference design uses a filter-based metering algorithm [2]. This particular algorithm calculates the billing and non-billing quantities according to formulas given in this section. Because of the use of digital filters, the algorithm requires only instantaneous voltage and current samples to be provided at constant sampling intervals. After a slight modification to the application software, it is also possible to use FFT based algorithms [3]. 4 Hardware design This section describes the power meter electronics. The power meter electronics are divided into three parts: • Power supply • Digital circuits • Analog signal conditioning circuits The power supply part of the hardware design is comprised of an 85–265 V AC-DC SMPS, a low-noise 3.6 V linear regulator, and a power management block. This power supply topology has been chosen to provide low-noise output voltages to supply the power meter electronics. The simple power management block works autonomously—that is, it supplies the power meter electronics from either the 50 Hz (60 Hz) mains or the 3.6 V Li-SOCI2 battery, which is also integrated. The battery serves as a backup supply in cases when the power meter is disconnected from the mains, or the mains voltage drops below 85 V AC. For more information, refer to Section 4.1, “Power supply.” The digital part can be configured to support both basic and advanced features. The basic configuration comprises only the circuits necessary for power meter operation—these are, the microcontroller (MKM34Z128MCLL5), debug interface, LCD interface, LED interface, IR (IEC1107), isolated open-collector pulse output, isolated RS232, push-button, and tamper detection. In contrast to the basic configuration, all the advanced features are optional and require the following additional components to be populated: 32 KB I2C EEPROM for data storage, 3-axis magnetometer for electronic tampering, and UMI and RF MC1323x-IPB interfaces for AMR communication and remote monitoring. For more information, see Section 4.2, “Digital circuits”. The Kinetis-M devices allow differential analog signal measurements with a common mode reference of up to 0.8 V and an input signal range of ±250 mV. The capability of the device to measure analog signals with negative polarity brings a significant simplification to the phase current sensors’ hardware interfaces. The phase voltage signal is simply connected to the SAR multiplexer, however, the external biasing circuits must be added externally (see Section 4.1, “Power supply”). The power meter electronics have been realized using a four-layer printed circuit board (PCB). We have chosen the more expensive four-layer PCB, comparing to a cheaper two-layer one, in order to validate the accuracy of the 24-bit SD ADC and 16-bit SAR ADC on the metering hardware optimized for measurement accuracy. Figure B-1and Figure B-2 show the top and bottom views of the power meter PCB. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 7 Hardware design 4.1 Power supply The user can use the 85–265 V AC-DC SMPS, which is directly populated on the PCB, or any other modules with different power supply topologies. If a different AC-DC power supply module is to be used, then the AC (input) side of the module must be connected to JP1, JP2, JP3, JP4, and the DC (output) side to JP1, JP5. The output voltage of the suitable AC-DC power supply module must be 4.0 V ±5%. As already noted, the reference design is pre-populated with an 85–265 V AC-DC SMPS power supply. This SMPS is non-isolated and capable of delivering a continuous current of up to 80 mA at 4.125 V [4]. The SMPS supplies the SPX3819 low dropout adjustable linear regulator, which regulates the output voltage (VPWR) by using two resistors (R20 and R21) according to the formula: R20 VPWR = 1.235 1 + ---------R21 Eqn. 10 The resistor values R20 = 45.3 kΩ and R21 = 23.7 kΩ were chosen to produce a regulated output voltage of 3.6 V. The following supply voltages are all derived from the regulated output voltage (VPWR): • VDD—digital voltage for the microcontroller and digital circuits • VDDA—analog voltage for the microcontroller’s 24-bit SD ADC and 1.2 V VREF • SAR_VDDA—analog voltage for the microcontroller’s 16-bit SAR ADC The regulated output voltage also supplies those circuits with higher current consumption: Isolated RS232 interface (U301 and U302), Isolated pulse output (U303), and potential external modules attached to the RF MC1323x-IPB connector (J350). All of these circuits operate in normal mode when the power meter is connected to the mains. The battery voltage (VBAT) is separated from the regulated output voltage (VPWR) using the D20 and D21 diodes. When the power meter is connected to the mains, then the electronics are supplied through the bottom D21 diode from the regulated output voltage (VPWR). If the power meter is disconnected from the mains, then D20 and the upper D21 diodes start conducting and the microcontroller device, including a few additional circuits operating in standby and power-down modes, are supplied from the battery (VBAT). The switching between the mains and battery voltage sources is performed autonomously, with a transition time that depends on the rise and fall times of the regulated output voltage supply (VPWR). The analog circuits within the microcontroller usually require decoupled power supplies for the best performance. The analog voltages (VDDA and SAR_VDDA) are decoupled from the digital voltage (VDD) by the chip inductors L20 and L21 and the small capacitors next to the power pins (C26, C27, C28, C29, C30, and C31). Using chip inductors is especially important in mixed signal designs such as a power meter application, where digital noise can disrupt precise analog measurements. The L20 and L21 inductors are placed between the analog supplies (VDDA and SAR_VDDA) and digital supply (VDD) to prevent noise from the digital circuitry from disrupting the analog circuitries. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 8 Freescale Semiconductor, Inc. Hardware design VD D DN P 85-265V A C-DC SMPS MODULE A D9 0 C 1 L9 0 15 0 0u H 2 U 90 MR A40 0 7T3G S1 S2 S3 S4 1 LN K3 02D N + C 90 4. 7 u F 2 1 D9 4 R 93 2. 0 K C 93 2 2uF 1% 1 J 20 H D R _1 X2 MR A 400 7 T3 G V OUT L91 1 50 0 uH 2 + C 91 4 . 7uF C9 4 1 C 20 JP 6 H DR 1 X1 1 D2 1 B AT54 C L T1 VP W R C 21 3 1 0U F 10U F 1 10 0 U F R 96 1. 6K VD D A 1 L 20 D 20 MMS D 414 8 T1 G A C Open J21 to monitor BT1 current. 3.6 V Battery 2 D 95 ES 1J L A HD R 1 X1 DN P 0. 1 u F 5 6 7 8 JP 4 1% C 92 J 21 H D R _1X2 BT20 BATTER Y R 94 3 . 0 K D HD R 1 X1 V OUT 1 2 L1 VP W R C 4 JP 1 DN P 1 D9 1 MR A40 0 7T3G C HD R 1 X1 A A VD D 1 MR A40 0 7T3G L2 VP W R C JP 2 DN P 1 C 2 1 HD R 1 X1 JP 5 H D R 1 X1 DN P U20 V IN VOU T 5 ADJ 4 1 uH 2 C 26 1uF VD D C 27 1uF C2 8 1uF VD D 2 C 24 GN D EN J 22 H D R _1 X2 3 1 2 A D9 2 1 2 L3 FB BP JP 3 DN P 1 R 20 45 . 3K C 22 C 23 10U F 10UF S AR _V D D A C 25 1 0 U F 1 0 UF 1 L21 1u H 2 C 29 1uF SPX38 19M5 -L C 30 1uF C3 1 1uF R 21 23 . 7K Figure 2. Power supply NOTE The digital and analog voltages VDD, VDDA and SAR_VDDA are lower by a voltage drop on the diode D21 (0.35 V) than the regulated output voltage VPWR. 4.2 Digital circuits All the digital circuits are supplied from the VDD and VPWR voltages. The digital voltage (VDD), because it is backed-up by the 1/2AA 3.6 V Li-SOCI2 battery (BT200), is active even if the power meter electronics are disconnected from the mains. It supplies the microcontroller device (U1), 32KB EEPROM, and the 3-axis magnetometer (U381). The regulated output voltage (VPWR) supplies the digital circuits that can be switched off during the standby and power-down operating modes. These components are: Isolated RS232 interface (U303), Isolated open-collector pulse output interface (U301 and U302), RF MC1323x-IPB interfaces (J350), and the IR Interface (Q1), if in use. 4.2.1 MKM34Z128MCLL5 The MKM34Z128MCLL5 microcontroller (U1) is the most noticeable component on the metering board (see Figure A-1). The following components are required for flawless operation of this microcontroller: • Filtering ceramic capacitors C1–C7 and C8–C11 • External reset filter C13 and R1 • 32.768 kHz crystal Y1 An indispensable part of the power meter is the Human Machine Interface (HMI) consisting of an LCD (DS300) and user push-button (SW371). The charge pump for the LCD is part of the MCU and it requires four ceramic capacitors (C8–C11) on the board. Two connectors (J361 and J362) are also populated to interface the terminal cover and the main cover switches to the MCU tamper detection circuit. Connector J1 is the SWD interface for MCU programming. CAUTION The debug interface (J1) is not isolated from the mains supply. Use only galvanically isolated debug probes for programming the MCU when the power meter is supplied from the mains supply. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 9 Hardware design 4.2.2 Output LEDs The microcontroller uses two GPIO pins or two timer channels to control the calibration LEDs (D351 and D352). The timers’ outputs are routed to the respective device pins (QT2 and QT3). The LED’s drive method is optional because the hardware supports both connections. The timer LED’s drive method is usually chosen to produce a low-jitter and high dynamic range pulse output waveform; the method for low-jitter pulse output generation using software and timer is being patented. VDD R 341 390 D351 WP7104LSR D C A R 342 390 D352 WP7104LSR D C A k W h_LED k VArh_LED R 343 1.0K USER_LED D353 C A HSMS-C170 Figure 3. Output LEDs control The user LED (D343) is driven by software through the GPIO output pin (PTD6). It blinks when the power meter enters the calibration mode, and turns solid after the power meter is calibrated and is operating normally. 4.2.3 Isolated open-collector pulse output interface Figure 4 shows the schematic diagram of the open collector pulse output. This may be used for switching loads with a continuous current as high as 50 mA and with a collector-to-emitter voltage of up to 70 V. The interface is controlled through the GPIO (PTF0) pin of the microcontroller, and hence it may be controlled by a variety of internal signals, for example, the timer channels generate the pulse outputs. The isolated open-collector pulse output interface is accessible on connector J302. R307 390 PULSE_OU T U303 SFH6106-4 2 3 2 1 VPW R 1 4 J 302 CO N TB 2 DN P Figure 4. Open-collector pulse output control The PTF0 pin also checks whether the VPWR is present. This use case is of PTF0 using the input mode. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 10 Freescale Semiconductor, Inc. Hardware design 4.2.4 IR interface (IEC1107) The power meter has a galvanically isolated optical communication port, as per IEC 1107 / ANSI / PACT, so that it can be easily connected to a hand-held common meter reading instrument for data exchange. The IR interface is driven by UART3. The UART3 pins are shared with the isolated RS232 interface. IR interface selection is populated by R312 and R314. The IR interface schematic is shown in Figure 5. R311 0 R312 0 DNP UAR T3_R XD_IR VPW R UART3_RXD_IR R322 1.0K 1 UART3_RXD UAR T3_R XD_RS232 R321 10.0K R314 0 DNP UART3_TXD C321 2200pF UAR T3_TXD _R S232 Q321 OP506B 2 R313 0 UAR T3_TXD _IR A UART3_TXD_IR R323 680 C D 321 TSAL4400 Figure 5. IR control 4.2.5 Isolated RS232 interface This communication interface is used primarily for real-time visualization using FreeMASTER [5]. The communication is driven by the UART3 module of the microcontroller. Communication is optically isolated through the optocouplers U301 and U302. In addition to the RXD and TXD communication signals, the interface implements two additional control signals, RTS and DTR. These signals are typically used for transmission control, however, this function is not used within this reference design. Because there is a fixed voltage level on the control lines generated by the PC, the Isolated RS232 interface is used to supply the secondary side of the U4 and the primary side of the U3 optocouplers. The communication interface, including the D301–D302, C301, R305, and R306 components, that are required to supply the optocouplers from the transition control signals, is shown in Figure 6. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 11 Hardware design R311 0 R312 0 DNP R313 0 R314 0 DNP U301 SF H6106-4 2 3 1 4 R305 4.7K R 304 1.0K 3 2 R306 470 J301 C301 2.2UF D301 MMSD 4148T1G D302 MMSD 4148T1G 1 3 5 7 9 2 4 6 8 10 A U AR T3_RXD_RS232 SF H6106-4 U302 A VPW R UAR T3_TXD _IR C U AR T3_TXD_R S232 R 302 390 UAR T3_TXD _R S232 A UART3_TXD UAR T3_R XD_IR C UART3_RXD UAR T3_R XD_RS232 HD R_2X5 4 1 C D303 MMSD 4148T1G Figure 6. RS232 control The UART3 pins are shared with the Isolated RS232 interface. The Isolated RS232 interface selection must be populated by R311 and R313. 4.2.6 MAG3110 3-axis magnetometer This sensor is optional and can be used for advanced tamper detection for current transformers. In the schematic diagram, the MAG3110 3-axis magnetometer is marked as U381 (see Figure 7). The magnetometer communicates with the microcontroller through the I2C1 data lines; therefore, the external pull-ups R3 and R4 on the SCL and SDA lines are required. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 12 Freescale Semiconductor, Inc. Hardware design C384 0.1UF 8 NC INT1 GND1 C383 0.1UF 5 C382 0.1U F SCL SD A 7 6 I2C1_SCL I2C1_SDA 9 C385 0.1U F GN D2 3 C381 1.0U F CAP_A CAP_R 10 1 4 U381 VDD IO VDD 2 VDD MAG3110 Figure 7. MAG3110 sensor control 4.2.7 4 KB I2C EEPROM The 32 KB I2C EEPROM U391 (AT24C32D) can be used for parameter storage. The microcontroller uses I2C1 for communication with the EEPROM. The I2C1 is shared with a magnetometer sensor. 1 2 3 4 U 391 A0 A1 A2 GND VCC WP SCL SDA 8 7 6 5 VDD I2C 1_SCL I2C 1_SDA AT24C32D C391 0.1UF Figure 8. 32 KB I2C EEPROM control 4.2.8 RF MC1323x-IPB interfaces The RF MC1323x-IPB interface (J350) is intended to interface the power meter with the Freescale ZigBee small-factor modules. This interface comprises connections to UART1 and the I2C1 peripherals, as well as to several I/O lines for module reset, handshaking, and control. VPW R J 350 R F_RST UART1_RTS UART1_CTS RF_IO 1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20 C 351 0.1UF UART1_TXD UART1_RXD I2C1_SDA I2C1_SCL RF_CTR L CON_2X10 Figure 9. RF MC1323x-IPB interfaces control Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 13 Hardware design NOTE RF MC1323x-IPB interfaces are designed to supply the external communication modules from the regulated output voltage VPWR. Therefore, use only communication modules with a supply voltage of 3.6 V and a continuous current of up to 60 mA. 4.3 Analog circuits Excellent performance of the metering AFE, including external analog signal conditioning, is crucial for a power meter application. The most critical performance aspect is the phase current measurement due to the high dynamic range of the current measurement (800:1 and higher) and the relatively low input signal range (from hundredths of millivolts up to volts). All analog circuits are described in the following subsections. 4.3.1 Phase current measurement The Kinetis-M three-phase power meter reference design is optimized for current transformers, but a variety of Rogowski coils can also be used. The only limitations are that the sensor output signal range must be within ±0.5 V peak and within the dimensions of the enclosure. The interface of a current sensor to the MKM34Z128MCLL5 device is very straightforward; a burden resistor for current-to-voltage conversion and anti-aliasing low-pass filters attenuating signals with frequencies greater than the Nyquist frequency must be populated on the board (see Figure 10). The cut-off frequency of the analog filters implemented on the board is 72.3 kHz; such a filter has an attenuation of -33.3 dB at Nyquist frequency of 3.072 MHz. The burden resistor is a composite formed by two resistors with the same value. The middle point of this is connected to ground. TP231 R233 22 SD ADP0 J 231 C ON TB 2 R 231 4.7 C231 0.047UF 1 2 D NP R 232 4.7 C232 0.047UF R234 22 SD ADM0 TP232 Figure 10. Phase current signal conditioning circuit Each of the three (or four) current channels use the same topology. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 14 Freescale Semiconductor, Inc. Hardware design Table 2. Current signal components 4.3.2 Channel Component 1 R231, R232, R233, R234, C231, C232 and J231 2 R241, R242, R243, R244, C241, C242 and J241 3 R251, R252, R253, R254, C251, C252 and J251 4 R261, R262, R263, R264, C261, C262 and J261 neutral current measurement Phase voltage measurement R201 220K J 201 C ON TB 2 R 204 100K D 201 BAV99LT1 2 3 L1 R206 1k R 207 47 TP201 SAR _AD0 SAR_AD0 1 RV201 20S0271 R205 1k DN P C 201 0.01UF 2 D NP R203 100K 1 2 1 R202 220K VREF/2 VD D A simple voltage divider is used for the line voltage measurement. In a practical implementation, it is better to design this divider from several resistors connected serially due to the power dissipation. One half of this total resistor consists of R201, R202, R203, and R204, the second half consists of resistor R205 (channel 1), R211, R212, R213, R214 and R215 (channel 2) and R221, R222, R223, R224 and R2025 (channel 3). The resistor values were selected to scale down the 325.26 V peak input line voltage to the 0.52272 V peak input signal range of the 16-bit SAR ADC. The SAR ADC input is unipolar different to bipolar SD ADC inputs, so for this case an external bias voltage must be added. External bias voltage is derived from the on-chip reference voltage (taken from the VREF pin) and the value is the half of reference voltage. The bias voltage is connected to the voltage diver through the second half resistors R205, R215 and R225. The voltage drop and power dissipation on each of the MELF02041 resistors are below 57.5 V and 22 mW, respectively. The anti-aliasing low-pass filter of the phase voltage measurement circuit is set to a cut-off frequency of 27.22 kHz. Such an anti-aliasing filter has an attenuation of -41.0 dB at Nyquist frequency of 3.072 MHz. Figure 11. Phase voltage signal conditioning circuit 4.3.3 Half reference voltage level generator The reference voltage half value is generated from internal voltage reference. Reference voltage 1.2V is available on the VREF pin. This voltage is simply divided by two through the voltage divider R281 and R282. The half reference voltage is connected to the unity gain buffer where the optional filter capacity C282 is added. The unity gain buffer is a low cost and simple instrumentation amplifier U281 LMV321. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 15 Software design A unity gain buffer is placed for phase voltage channel decoupling, therefore, the buffer works like an impedance transformer. Figure 12 shows the schematic diagram of the half reference voltage generator. VPW R 5 VREF R281 10K 3 - 1 + U281 V+ LMV321 4 VR EF/2 C281 0.1UF 2 VR282 10K C282 0.1UF Figure 12. Half reference voltage level generator 4.3.4 Zero crossing circuits connection The low level phase voltage from the voltage dividers is connected to the analog comparator inputs through R271, R272 and R273. Optional capacitors C271, C272, and C273 are added to the signal path for additional filtering. SAR _AD0 R 271 10K CMP0_P0 C271 1000pF Figure 13. Zero crossing circuits 5 Software design This section describes the software application of the Kinetis-M three-phase power meter reference design. The software application consists of measurement, calculation, calibration, user interface, and communication tasks. 5.1 Block diagram The application software has been written in C-language and compiled using the IAR Embedded Workbench for ARM (version 6.60.0) with full optimization for execution speed. The software application is based on the Kinetis-M bare-metal software drivers [7] and the filter-based metering algorithm library [2]. The software features are as follows: • Transitions between operating modes, • Performs a power meter calibration after first start-up, Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 16 Freescale Semiconductor, Inc. Software design • • • • • Calculates all metering quantities, Controls the active and reactive energies pulse outputs, Runs the HMI (LCD display and button), Stores and retrieves parameters from the NVMs, Enables application remote monitoring and control. The application monitoring and control is performed through FreeMASTER. Figure 14 shows the software architecture of the power meter including interactions of the software peripheral drivers and application libraries with the application kernel. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 17 Software design Figure 14. Software architecture All tasks executed by the Kinetis-M one-phase power meter software are briefly explained in the following subsections. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 18 Freescale Semiconductor, Inc. Software design 5.2 Software tasks The software tasks are part of the application kernel. They’re driven by events (interrupts) generated either by the on-chip peripherals or the application kernel. The list of all tasks, trigger events, and calling periods are summarized in Table 3. Table 3. List of software tasks Task name Power meter calibration Description Source file(s) Performs power meter calibration and stores calibration parameters config.c config.h Function name Trigger source CONFIG_UpdateOffsets device reset CONFIG_CalcCalibData Interrupt priority Calling period — after first device reset, and a special load point is applied by the test equipment Operating mode Controls transitioning control between power meter operating modes mk341ph.c main device reset — after every device reset Data processing Reads digital values from the AFE, SAR, and performs scaling main.c afech0_callback afech1_callback afech2_callback AFE CH0 AFE CH1 AFE CH2 conversion complete interrupt Level 0 (highest) periodic 166.6 μs Calculation; Calculates billing and billing quantities non-billing quantities — auxcalc_callback — Level 1 periodic 833.3 μs Calculation; non-billing quantities — — — — — — HMI control Updates LCD with new values and transitions to new LCD screen after user button is pressed — display_callback — Level 3 (lowest) periodic 250 ms Application monitoring freemaster_*.c and control freemaster_*.h FreeMASTER communication Recorder Parameter management Writes/reads parameters from the Flash 5.2.1 FMSTR_Init UART3 Rx/Tx Level 2 interrupts asynchronous — FMSTR_Recorder AFE CH2 conversion complete interrupt Level 1 periodic 833.3 μs config.c config.h CONFIG_SaveFlash CONFIG_ReadFlash after successful calibration or controlled by user — — Power meter calibration The power meter is calibrated with the help of test equipment. The calibration task runs whenever a non-calibrated power meter is connected to the mains. The running calibration task measures the phase Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 19 Software design voltage and phase current signals generated by the test equipment; it scans for a 230 V phase voltage and 5.0 A phase current waveforms with a 45 degree phase shift. If the calibration task detects such a load point, then, after 35 s of collecting data, the calibration task calculates the calibration offsets, gains, and phase shift using the following formulas: gain u = 230 ⁄ URMS Eqn. 11 gain I = 5.0 ⁄ IRMS -1 Q θ comp = 45° – tan ---- R Eqn. 12 Eqn. 13 where gainu , gainI are calibration gains, θcomp, is the calculated phase shift caused by current transformers, and URMS, IRMS, Q, P are quantities measured by the non-calibrated meter. Contrary to the gain and phase shift calculations that are based on RMS values, the calibration offsets are calculated from instantaneous measured samples, as follows: n n max u ( k ) – min u ( k ) k =0 k =0 offset u = ---------------------------------------------------------------------------------------------------2 n n max i ( k ) – min i ( k ) k =0 k =0 offset I = ------------------------------------------------------------------------------------------------2 Eqn. 14 Eqn. 15 where offsetu, offsetI are calculated calibration offsets, u(k), i(k) are respectively the instantaneous phase voltage and phase current samples in measurement steps k=0,1, … n. The calibration task terminates by storing calibration gains, offsets and phase shift into the flash and by resetting the microcontroller device. The recalibration of the power meter can also be initiated from FreeMASTER. 5.2.2 Operating mode control The transitioning of the power meter electronics between operating modes helps maintain a long battery lifetime. The power meter software application supports the following operating modes: • Normal (electricity is supplied, causing the power meter to be fully-functional) • Standby (electricity is disconnected, and the user navigates through menus) • Power-down (electricity is disconnected, but there is no user interaction) Figure 15 shows the transitioning between supported operating modes. After a battery or the main power is applied, the power meter transitions to the device reset state. If the mains have been applied, then the software application enters normal mode and all software tasks including calibration, measurements, calculations, HMI control, parameter storage, and communication are executed. In this mode, the MKM34Z128MCLL5 device operates in run mode. The system clock frequency is generated by the FLL and is 48 MHz. The power meter electronics consume 18.4 mA. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 20 Freescale Semiconductor, Inc. Software design If the mains have not been applied, then the software application enters standby mode. In this mode, the power meter runs from battery. All software tasks are stopped except HMI control. In this mode, the MKM34Z128MCLL5 device executes in VLPR mode. The system clock frequency is downscaled to 125 kHz from the 4 MHz internal relaxation oscillator. Because of the slow clock frequency, the limited number of enabled on-chip peripherals, and the Flash module operating in a low-power run mode, the power consumption of the power meter electronics is 260 µA. Finally, when the power meter runs from battery but the user does not navigate through the menus, then the software transitions automatically to the power-down mode. The MKM34Z128MCLL5 device is forced to enter VLLS2 mode, where recovery is only possible when either the user button is pressed or the mains is supplied. The power-down mode is characterized by a current consumption of 6.5 µA. Figure 15. Operating modes 5.3 Data processing Reading the phase voltage from the SAR ADC and phase current samples from the analog front-end (AFE) occurs periodically every 166.6 µs. This task runs on the highest priority level (Level 0) and is triggered asynchronously when the AFE result registers receive new samples. The task reads the phase voltage and phase current samples from the AFE result registers, scales the samples to the full fractional range, and writes the values to the temporary variables for use by the calculation task. 5.3.1 Data sampling The phase voltage and phase current must be sampled at the same time, because the power calculations are defined as are the multiplication of the immediate voltage and current values in Equation 7 and Equation 8. The voltage signal is sampled by the one SAR ADC with an input multiplexor, because of this, all six signals (3x phase voltage and 3x phase current) cannot be sampled at the same time. The sampling of the different phase signals must be time shifted. This can be easily implemented by using the AFE delay start function. Each AFE channel start is delayed from the previous channel. CH0 begins conversion at the time Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 21 Software design 0 × FDL, CH1 begins conversion at the time 1 × FDL, and CH2 begins conversion at the time 2 × FDL. The FDL (Fix Delay) constant is longer than the SAR conversion time plus multiplexor switching time. The internal interconnection between AFE and SAR is implemented through the XBAR peripherals. The AFE COCO CHx (COCO—conversion complete, for continued AFE mode conversion start) is used for the hardware trigger conversion start for SAR. Typically, current sensors generate phase shift between phase voltage and phase current, because current signal is converted on the voltage signal. Voltage signal is needed for ADC. The voltage to current conversion takes time, called phase shift error. The sensor phase shift error can be compensated to add delay time between the AFE COCO signal and the SAR hardware conversion trigger. This requirement can also be resolved through the XBAR. The signal chain AFE COCO and SAR hardware trigger should be extended by adding the next block between AFE and SAR to generate the time delay. The ideal hardware resource for this task is a Quad Timer, because it can operate in One-Shot mode. The signal chain for the sensor’s phase shift compensation is; AFE connected to the TMR which is connected to the SAR. AFE COCO signal begins the TMR and then TMR, after a delay, passes the signal to SAR which generates the hardware trigger signal. The three phase application uses three current sensors with different phase shift errors, for this reason, it is during the calibration process that the three compensation times for each channel are calculated. 166us OSR1024 166us OSR1024 Sigma-Delta CH0 166us OSR1024 Sigma-Delta CH0 Sigma-Delta CH0 COCO S-D CH0 9us + x 166us OSR1024 FDL COCO S-D CH0 166us OSR1024 Sigma-Delta CH1 166us OSR1024 Sigma-Delta CH1 Sigma-Delta CH1 COCO S-D CH1 2 * (9us + x) FDL 166us OSR1024 FDL t 166us OSR1024 Sigma-Delta CH2 t COCO S-D CH1 166us OSR1024 Sigma-Delta CH2 Sigma-Delta CH2 COCO S-D CH2 TMR 0 COCO S-D CH2 t TMR 0 TMR 1 TMR 1 TMR 2 TMR 2 9us 9us 9us 9us 9us 9us SAR CH0 SAR CH1 SAR CH2 SAR CH0 SAR CH1 SAR CH2 0 t Figure 16. Three-phase sampling signal chain with HW based phase shift error compensation Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 22 Freescale Semiconductor, Inc. Software design The other possible method to compensate for current sensor phase shift error is a software based solution. The sample’s value is scaled with respect to the phase shift error. This correction algorithm can also be implemented in the time and frequency domains. 166us OSR1024 166us OSR1024 Sigma-Delta CH0 166us OSR1024 Sigma-Delta CH0 COCO S-D CH0 9us + x 166us OSR1024 FDL Sigma-Delta CH0 COCO S-D CH0 166us OSR1024 Sigma-Delta CH1 166us OSR1024 Sigma-Delta CH1 COCO S-D CH1 2 * (9us + x) FDL 166us OSR1024 FDL Sigma-Delta CH1 COCO S-D CH1 166us OSR1024 Sigma-Delta CH2 t t 166us OSR1024 Sigma-Delta CH2 COCO S-D CH2 Sigma-Delta CH2 COCO S-D CH2 9us 9us 9us 9us 9us 9us SAR CH0 SAR CH1 SAR CH2 SAR CH0 SAR CH1 SAR CH2 0 t t Figure 17. Two Three-phase sampling signal chain with SW based phase shift error compensation Both methods offer advantages and disadvantages. The hardware based method uses pure sampling for the next calculation, therefore no calculation rounding error is incurred. The software based method saves the microcontroller’s resources (three channels of TMR). For example, the TMRs can be used for direct drive output LEDs to produce very low jitter of the output pulses. 5.4 Calculations The execution of the calculation task is carried out periodically every 833.3 µs. The calculation task scales the samples using calibration offsets and calibration gains obtained during the calibration phase: u_sample scaled = gain u ( u_sample – offset u ) i_sample scaled = gain I ( i_sample – offset I ) Eqn. 16 Eqn. 17 where u_sample and i_sample are measured samples, offsetu, offsetI, gainu, and gainI are calibration parameters. The scaled samples are then used by the metering algorithm. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 23 Software design NOTE We found experimentally that increasing the calculation update rate beyond 1200 Hz doesn’t improve the accuracy of the measurement or calculations. 5.5 HMI control The Human Machine Interface (HMI) control task executes in a 250 ms loop and on the lowest priority (Level 3). It reads the real-time clock, calculates the mains frequency, and formats data into a string that is displayed on the LCD. The interaction with the user is arranged through an asynchronous event, which occurs when the user button is pressed. By pressing the user button, you may scroll through menus and display all measured and calculated quantities (see Table 5). 5.6 FreeMASTER communication FreeMASTER establishes a data exchange with the PC. The communication is fully driven by the UART3 Rx/Tx interrupts, which generate interrupt service calls with priority Level 2. The power meter acts as a slave device answering packets received from the master device (PC). The recorder function is called by the calculation task every 833.3 µs. The priority setting guarantees that data processing and calculation tasks are not impacted by the communication. For more information about using FreeMASTER, refer to Subsection 6.6-Error: Reference source not found. 5.7 Parameter management The current software application uses the last 1024 bytes sector of the internal Flash memory of the MKM34Z128MCLL5 device for parameter storage. By default, parameters are written after a successful calibration and read following a device reset. In addition, storing and reading parameters can be initiated through FreeMASTER. 5.8 Performance Table 4 shows the memory requirements of the Kinetis-M one-phase power meter software application1. Table 4. Memory requirements Flash size [KB] RAM size [KB] Complete application without the metering library and FreeMASTER 21.6 0.3 Filter-based metering algorithm library Filter-based metering algorithm library 8.3 2.8 FreeMASTER FreeMASTER protocol and serial communication driver 4.1 2.2 34.0 5.3 Function Description Application framework Total: 1. The application is compiled using the IAR Embedded Workbench for ARM (version 6.60) with full optimization for execution speed. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 24 Freescale Semiconductor, Inc. Software design The software application reserves the 4.0 KB RAM for the FreeMASTER recorder. If the recorder is not required, or a fewer number of variables will be recorded, you may reduce the size of this buffer by modifying the FMSTR_REC_BUFF_SIZE constant (refer to the freemaster_cfg.h header file, line 72). The system clock for AFE is generated by the PLL. In normal operating mode, the PLL multiplies the clock of an external 32.768 kHz crystal by a factor of 375, hence generating a low-jitter clock with a frequency of 12.288 MHz. NOTE The filter-based metering algorithm configuration tool estimates the minimum system clock frequency for the ARM Cortex-M0+ core to calculate billing and non-billing quantities with an update rate of 1200 Hz to approximately 8.4 MHz for one phase calculation. As shown in Figure 18, by slowing down the update rate of the non-billing calculations from 1200 to 600 Hz and further reducing the Hilbert-filter length from 49 to 39-taps, the required performance will eventually decrease by 32.14% to 5.7 MHz for one-phase calculation. Figure 18. Minimum system clock requirements for the filter-based metering algorithm Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 25 Application set-up 6 Application set-up Figure 19 shows the wiring diagram of the Kinetis-M three-phase power meter. User LED User button Re-active energy LED Active energy LED L1 L2 L3 N Figure 19. Kinetis-M Three-phase power meter – wiring diagram Among the main capabilities of the power meter, is registering the active and reactive energy consumed by an external load. After connecting the power meter to the mains, or when you press the user button, the power meter transitions from the power-down mode to either the normal mode or standby mode, respectively. In normal and standby modes, the LCD is turned on and shows the last quantity. The user can navigate through the menus and display other quantities by pressing the user button. All configuration and informative quantities accessible through the LCD are summarized in Table 5. Table 5. Quantities shown on the LCD Value Units Format OBIS Code Date year, month, day YYYY:MM:DD 0.9.2 Time hour, min, sec HH:MM:SS 0.9.1 Line voltage; L1, L2, L3 VRMS #.# V — Line current; L1, L2, L3 IRMS #.### A — Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 26 Freescale Semiconductor, Inc. FreeMASTER visualization Table 5. Quantities shown on the LCD (continued) Value Units Format OBIS Code W #.### W (+ forward, - reverse) 1.6.0 Signed reactive power; L1, L2, L3 VAr #.### VAr (+ lag, - lead) — Apparent power: L1, L2, L3 VA #.### VA — kWh #.### kWh (+ import, - export) 1.9.0 kVArh #.### kVArh (+ import, - export) — Frequency Hz ##.# Hz — Software revision-product serial number — #.#.# - ### (revision – meter serial number) — Class according to EN50470-3 — C # #-###A (example C 5-120A) — Signed active power; L1, L2, L3 Signed active energy Signed reactive energy 7 FreeMASTER visualization The FreeMASTER data visualization and calibration software is used for data exchange [5]. The FreeMASTER software running on a PC communicates with the Kinetis-M three-phase power meter over an isolated RS232 interface. The communication is interrupt driven and is active when the power meter is powered from the mains. The FreeMASTER software enables remote visualization, parameterization, and calibration of the power meter. It runs visualization scripts which are embedded into a FreeMASTER project file. Before running a visualization script, the FreeMASTER software must be installed on your PC. After installation, a visualization script may be started by double-clicking on the monitor.pmp file. Once started, the visualization script shown in Figure 20 will appear on your computer screen. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 27 FreeMASTER visualization Figure 20. FreeMASTER visualization software Next, you should set the proper serial communication port and communication speed in the Project/Option menu (see Figure 21). After communication parameters are properly set and the Stop button is released, the communication is initiated. A message on the status bar signals the communication parameters and successful data exchange. Figure 21. Communication port setting Now you can see the measured phase voltages, phase current, active, reactive, and apparent powers, pulse numbers, and additional status information in FreeMASTER. You may also visualize some variables in a graphical representation by selecting the respective scope or recorder item from the tree. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 28 Freescale Semiconductor, Inc. FreeMASTER visualization The visualization script enables you to monitor and parameterize the majority of the power meter features. To eliminate inappropriate and unwanted changes, some key parameters are protected by a 5-digit system password. These key parameters are as follows: • Set Calendar • Set Imp/kWh • Set Imp/kVARh • Recalibration All the remaining parameters and commands can be executed anytime, without the need for entering the system password: • LCD Screen Select • Software Reset • Clear Energy Counters • Clear Tampers Most of all, FreeMASTER will be used for monitoring the power meter operation and analyzing the phase voltages and phase currents waveforms in real-time. The visualization script file contains the following visualization objects: • Recorders (833 µs update rate, the number of samples is optional but limited to 4096 bytes) — Raw instantaneous phase voltage and current samples — High-pass filtered instantaneous phase voltage and current samples • Scopes (10 ms update rate, the number of samples unlimited) — Energy profile (kWh and kVARh counters with resolution 10-5) — RMS voltage, RMS current, active power, reactive power, and apparent power. — Power meter’s actual date and time — Mains frequency • Variables and Enumerations (shown in text form) — Password set-up — Tamper status — Remote command Figure 22 shows the high-pass filtered phase voltage and phase current waveforms with shorted input terminals. The waveform samples are captured every 833 µs and stored in a dedicated buffer of the MKM34Z128MCLL5 device. When the buffer is full, the data is sent to the PC via the optical port interface. The FreeMASTER visualization tool then displays the data on the PC screen. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 29 Accuracy and performance Figure 22. Recorded phase voltage and phase current waveforms Advanced users benefit from FreeMASTER’s built-in, active-x interface that serves to exchange data with other signal processing and programming tools, such as Matlab, Excel, LabView, and LabWindows. 8 Accuracy and performance As already indicated, the Kinetis-M three-phase reference designs have been calibrated using the test equipment ELMA8303 [1]. All power meters were tested according to the EN50470-1 and EN50470-3 European standards for electronic meters of active energy classes B and C, the IEC 62053-21 and IEC 62052-11 international standards for electronic meters of active energy classes 2 and 1, and the IEC 62053-23 international standard for static meters of reactive energy classes 2 and 3. During accuracy calibration and testing, the power meter measured electrical quantities generated by the test bench, calculated active and reactive energies, and generated pulses on the output LEDs; each generated pulse was equal to the active and reactive energy amount kWh (kVARh)/imp3. The deviations between pulses generated by the power meter and reference pulses generated by test equipment defined the measurement accuracy. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 30 Freescale Semiconductor, Inc. Accuracy and performance 8.1 Room temperature accuracy testing Figure 23 shows the calibration protocol of the power meter S/N: 35. The protocol indicates the results of the power meter calibration performed at 25°C. The accuracy and repeatability of the measurement for various phase currents and angles between phase current and phase voltage are shown in these graphs. The first graph (on the top) indicates the accuracy of the active and reactive energy measurement after calibration. The x-axis shows variation of the phase current, and the y-axis denotes the average accuracy of the power meter computed from five successive measurements; the gray lines define the Class C (EN50470-3) accuracy margins. The second graph (on the bottom) shows the measurement repeatability; i.e. standard deviation of error of the measurements at a specific load point. Similarly to the power meter accuracy, the standard deviation has also been computed from five successive measurements. 1 ERR [%] - Active and Reactive Energies 0.8 (unity an d o th er power fa ctors PF) 0.6 0.4 PF=1 PF=0.8C(R) PF=0.8C(A) PF=0.707L(R) PF=0.707L(A) PF=0.5L(R) PF=0 0.2 0 -0.2 -0.4 -0.6 -0.8 -1 0.015 0.05 0.1 0.25 0.375 0.5 1 2 5 10 In [A] 25 40 60 80 100 120 0.2 STDEV [%] - Standard Deviation 0.18 (calcu lated from 5 per-two p ulses measurements) 0.16 0.14 PF=1 PF=0.8C(R) PF=0.8C(A) PF=0.5L(R) PF=0.5L(A) PF=0 0.12 0.1 0.08 0.06 0.04 0.02 0 0.05 0.1 0.25 0.5 1 2 5 10 25 40 60 80 In [A] Figure 23. Calibration protocol at 25°C By analyzing the protocols of several Kinetis-M three-phase power meters, it can be said that this equipment measures active and reactive energies at all power factors, at 25°C ambient temperature, and in the current range 0.25–120 A4, more or less with an accuracy range ±0.25%. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 31 Summary 9 Summary This design reference manual describes a solution for a three-phase electronic power meter based on the MKM34Z128CLL5 microcontroller. Freescale Semiconductor offers filter and FFT based metering algorithms for use in customer applications. The former calculates metering quantities in the time domain, the latter in the frequency domain. This reference manual explains the basic theory of power metering and lists all the equations to be calculated by the power meter. The hardware platform of the power meter is algorithm independent, so application firmware can leverage any type of metering algorithm based on customer preference. To extend the power meter uses, the hardware platform comprises a 32 KB I2C EEPROM for data storage, an MAG3110 3-axis multifunction digital magnetometer for enhanced tampering, and RF MC1323x-IPB interfaces for AMR communication and monitoring. The application software has been written in C-language and compiled using the IAR Embedded Workbench for ARM (version 6.60), with full optimization for the execution speed. It is based on the Kinetis-M bare-metal software drivers [7]. The application firmware automatically calibrates the power meter, calculates all metering quantities, controls active and reactive energy pulse outputs, runs the HMI (LCD and button), stores and retrieves parameters from Flash memory, and enables monitoring of the application, including recording selected waveforms through FreeMASTER. An application software of such complexity requires 29.9 KB of flash and 6.6 KB of RAM. The system clock frequency of the MKM34Z128CLL5 device must be 48 MHz to calculate all metering quantities with an update rate of 1200 Hz. The power meter is designed to transition between three operating modes. It runs in normal mode when it is powered from the mains. In this mode, meter electronics consume 18.4 mA. The second mode, standby mode, is entered when the power meter runs from the battery and the user navigates through the menus. In this particular mode, the 3.6V Li-SOCI2 (1.2Ah) battery is discharged by 260 µA, resulting in 4,100 hours of operation (0.47 year battery lifetime). Finally, when the power meter runs from the battery but no interaction with the user occurs, the power meter electronics automatically transition to the power-down mode. The power-down mode is characterized by a current consumption as low as 6.5 µA, which results in 143,000 hours of operation (16.3 year battery lifetime). The application software enables you to monitor measured and calculated quantities through the FreeMASTER application running on your PC. All internal static and global variables can be monitored and modified using FreeMASTER. In addition, some variables, for example phase voltages and phase currents, can be recorded in the RAM of the MKM34Z128CLL5 device and sent to the PC afterwards. This power meter capability helps you to understand the measurement process. The Kinetis-M three-phase power meters were tested according to the EN50470-1 and EN50470-3 European standards for electronic meters of active energy classes B and C, the IEC 62053-21 and IEC 62052-11 international standards for electronic meters of active energy classes 2 and 1, and the IEC 62053-23 international standard for static meters of reactive energy classes 2 and 3. After analyzing several power meters, we can state that this equipment measures active and reactive energies at all power factors, a 25°C ambient temperature, and in the current range 0.25–120 A, more or less with an accuracy range ±0.25%. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 32 Freescale Semiconductor, Inc. References In summary, the capabilities of the Kinetis-M three-phase power meter fulfill the most demanding European and international standards for electronic meters. 10 References 1. Electricity Meter Test Equipment ELMA 8x01, from Applied Precision s.r.o, www.appliedp.com/en/elma8x01.htm 2. Filter-Based Algorithm for Metering Applications, by Martin Mienkina, Freescale Semiconductor, (Document number: AN4265), www.freescale.com/files/32bit/doc/app_note/AN4265.pdf 3. FFT-Based Algorithm for Metering Applications, by Ludek Slosarcik, Freescale Semiconductor, (Document number AN4255), www.freescale.com/files/32bit/doc/app_note/AN4255.pdf 4. LinkSwitch-TN Family Design Guide—AN37, from Power Integrations, April 2009, www.powerint.com/sites/default/files/product-docs/an37.pdf 5. FreeMASTER Data Visualization and Calibration Software, Freescale Semiconductor, www.freescale.com/webapp/ sps/site/prod_summary.jsp?code=FREEMASTER 6. UMI-S-001 - Main UMI specification, from Cambridge Consultants Ltd, http://umi.cambridgeconsultants.com 7. Kinetis M Bare-metal Software Drivers, from Freescale Semiconductor, September 2013, www.freescale.com/webapp/Download?colCode=KMSWDRV_SBCH 11 Revision history Revision 0 is the initial release of this document. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 33 Board electronics I2C Pul l-up`s UART3_TX /RESED T I2C1_SDA I2C1_SCL RF_ CTRL USER_B TN SWD_IO VDD R3 4.7K SWD_CLK R4 4.7K I2 C1_ SCL I2 C1_ SDA R5 0 R6 0 PTI0 LCD_15 LCD_16 LCD_17 LCD_18 LCD_19 LCD_20 UA RT1_CTS UART1_RTS CMP0_P5 DNP External Pul l-up`s for open-drain pins PTI0 UART1_TXD R9 4.7K 91 92 93 94 UART1_RTS UART1_TXD SDADP0 SDADM0 35 36 SDADP1 SDADM1 VBAT VDDA 42 43 C4 0.1UF SDADP3 SDADM3 41 VREFH SAR_VDDA 61 SAR_VDDA VBAT 37 VREF VREF VREF VREFH C6 0.1UF VREFL C7 0.1UF LC D BIAS and charge pump capac itors VCAP1 PTG0/LCD7/QT1/LPTIM2 PTG1/LCD8/AD10/ LLWU_P2/LPTIM0 PTG2/LCD9/AD11/ SPI0_SS/LLWU_P1 PTG3/LCD10/SPI0_SCK/I 2C0 _SCL PTG4/LCD11/SPI0_MOSI /I2C0_SDA PTG5/LCD12/SPI0_MISO/LPTIM1 PTG6/LCD13/LLWU_P0/L PTIM2 PTG7/LCD14 VCAP2 C9 0.1UF VLL2 PTI0/CMP0P5/SCI1_RXD/PXBAR_I N8/ SPI1_MISO/ SPI1_MOSI PTI1/SCI1_TXD/PXBAR_OUT8/ SPI 1_MOSI/SPI 1_MISO PTI2/LCD21 PTI3/LCD22 C1 0 0.1UF VLL3 C1 1 0.1UF PKM34Z128CLL5 UART1_RXD JP5 HDR 1X1 C DNP L90 15 00uH 2 0.1uF D94 R93 2.0 K 1% C93 22uF LNK30 2DN 1 + C91 4.7uF L91 1500uH 2 D95 ES1JL C94 1 00UF R96 1.6K A + C90 4. 7uF Connec t phase and neutral to the JP1, J P2, JP3 and JP4 he aders, respec tively: JP1, J P2 and JP3: Phase v oltage JP4: N eutral voltage J20 HDR_1X2 MRA4007T3G VOUT VOUT = 1.65V x [ (R40+R41)/R41] (4.12 V) Don't populate AC-D C SMPS if external power supply module is used instead. C onnect input of the external po wer supply module t o JP1, JP2 and JP3 (Line Input) and JP 4 (Neutral). Output voltage of t he external power s upply module must b e connected to JP5 (Vout) and JP6 (GND). 1 D21 BAT54CLT1 1 C21 10UF 10UF 2 3 U20 VI N VOUT 5 ADJ 4 C22 C23 10UF 10UF C25 10UF 10UF 1 SPX3819M5-L DNP Open J2 0 to power board f rom +5V laborat ory power supply. C26 1uF VDD 2 R20 45.3K TP1 TP2 TP3 C27 1uF C28 1uF VDD VDDA SAR_VDDA VBAT TP4 TP5 TP6 TP7 TP8 /RESET VDD C24 GND EN J22 HDR_1X2 3 VDDA 1 L20 1u H 2 Open J22 to monitor MCU + RTC currents. VPWR C20 JP6 HDR 1X1 D20 MMSD4148T1G A C Open J21 to monitor B T1 current. 3.6 V Ba ttery C 1 HDR 1X1 DNP 1% C92 1 1 2 S1 S2 S3 S4 Keep > =5mm distance betwee n JP1 and JP3 C U90 MRA4007T3G D HDR 1X1 2 Place clo se to VDDA pin of th e MCU J21 HDR_1X2 BT20 BATTERY R94 3. 0K A C 1 4 D9 0 VOUT 1 2 85-265V AC -DC SMPS MO DU LE 2 1 A Tes t Points C MRA4007T3G L1 FB BP A HDR 1X1 D9 1 C1 4 0.1UF 1 MRA4007T3G L2 VREF VDD VPWR VPWR 1 2 A D9 2 1 L3 HDR 1X1 JP4 C8 0.1UF VLL1 PTH0/LCD15 PTH1/LCD16 PTH2/LCD17 PTH3/LCD18 PTH4/LCD19 PTH5/LCD20 PTH6/SCI1_ CTS/SPI1_SS/ PXBAR_IN7 PTH7/SCI1_ RTS/SPI1_SCK/PXBAR_OUT7 Vref dec oupli ng JP1 DNP 1 SAR_VDDA C5 0.1UF VDD JP2 DNP 1 VDDA SDADP2 SDADM2 UART1_TXD UART1_RXD JP3 DNP 1 VDD C3 0.1UF VREFL UART1_CTS UART1_RTS 33 34 PTF0/AD7/RTCCLKOUT/QT2/ CMP0OUT PTF1/L CD0/ AD8/QT0/PXBAR_OUT6 PTF2/L CD1/ AD9/CMP1OUT/RTCCLKOUT PTF3/L CD2/ SPI 1_SS/LPTIM1/SCI0 _RXD PTF4/L CD3/ SPI 1_SCK/LPTI M0/SCI0_TXD PTF5/L CD4/ SPI 1_MISO/I 2C1_SCL/LLWU_P4 PTF6/L CD5/ SPI 1_MOSI/I 2C1_SDA/LLWU_P3 PTF7/L CD6/ QT2 /CLKOUT R10 4. 7K UART1_CTS TAMPER0 TAMPER1 PTE0/I 2C0_SDA/PXBAR_OUT4/SCI3_TXD/CLKOUT PTE1/RESET PTE2/EXTAL 1/EWM_IN/PXBAR_IN6/I2C1_SDA PTE3/XTAL1/EWM_OUT/AFE_CLK/ I2C1_SCL PTE4/L PTIM0/SCI2_CTS/ EWM_IN PTE5/QT3/ SCI2_RTS/EWM_OUT/LLWU_P6 PTE6/CMP0P2/PXBAR_IN5/SCI2_RXD/LLWU_P5/SWD_I O PTE7/AD6/PXBAR_OUT5/ SCI2_TXD/SWD_CLK 11 27 59 95 R8 4. 7K LCD_21 LCD_22 83 84 85 86 87 88 89 90 30 29 28 SAR_VDDA PTD0/CMP0P0/SCI0_ RXD/ PXBAR_IN2/LLWU_P11 PTD1/SCI1_ TXD/SPI0_SS/PXBAR_ OUT3/ QT3 PTD2/CMP0P1/SCI1_ RXD/ SPI0_SCK/PXBAR_IN3/ LLWU_P10 PTD3/SCI1_ CTS/SPI0_MOSI PTD4/AD3/SCI1_RTS/SPI0_MISO/ LLWU_P9 PTD5/AD4/L PTIM2/QT0/ SCI3_CTS PTD6/AD5/L PTIM1/CMP1OUT/SCI3_RTS/LLWU_P8 PTD7/CMP0P4/I2C0_SCL /PXBAR_IN4/ SCI3_RXD/LLWU_P7 VSS1 VSS2 VSS3 VSS4 VDD R7 4.7K 75 76 77 78 79 80 81 82 LCD_7 LCD_8 LCD_9 LCD_10 LCD_11 LCD_12 LCD_13 LCD_14 Shared pi ns selec tion UART1_RXD 67 68 69 70 71 72 73 74 PULSE_OUT LCD_0 LCD_1 LCD_2 LCD_3 LCD_4 LCD_5 LCD_6 I 2C1_SCL I 2C1_SDA 55 56 57 58 63 64 65 66 C2 0.1UF SAR_VSSA C18 18PF DNP VDD XTAL32K EXTAL32K 39 40 SDADP3/ CMP1P4 SDADM3/ CMP1P5 60 32. 768KHz C17 18PF DNP CMP0_P0 kWh_LED CMP0_P1 RF_ RST RF_IO kVArh_LED USER_LED UART3_RXD 1 47 48 49 50 51 52 53 54 SDADP1 SDADM1 SDADP2/ CMP1P2 SDADM2/ CMP1P3 PTC0/LCD39/SCI 3_RTS/PXBAR_IN1 PTC1/LCD40/CMP1P1/SCI 3_CTS PTC2/LCD41/SCI 3_TXD/PXBAR_OUT1 PTC3/LCD42/CMP0P3/SCI 3_RXD/ LLWU_P13 PTC4/LCD43 PTC5/AD0/SCI0_RTS/LLWU_ P12 PTC6/AD1/SCI0_CTS/QT1 PTC7/AD2/SCI0_TXD/PXBAR_OUT2 VDD VDD2 25 XTAL32K 26 EXTAL32K SDADP0 SDADM0 VREFL Y1 2 19 20 21 22 23 44 45 46 LCD_39 LCD_40 LCD_41 LCD_42 LCD_43 SAR_AD0 SAR_AD1 SAR_AD2 XTAL32K Watch crystal EXTAL32 K C13 0 .1UF VDD1 C1 0.1UF TAMPER0 TAMPER1 TAMPER2 VSSA /RESET Bypass Capac itors PTB0/L CD31 PTB1/L CD32 PTB2/L CD33 PTB3/L CD34 PTB4/L CD35 PTB5/L CD36 PTB6/L CD37/ CMP1P0 PTB7/L CD38/ AFE_CLK 32 R2 820 9 12 13 14 15 16 17 18 LCD_31 LCD_32 LCD_33 LCD_34 LCD_35 LCD_36 LCD_37 LCD_38 5 6 7 8 Freescale Semiconductor, Inc. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 SWD_RESET R1 4.7K 38 VDD External MCU Res et PTA0/L CD23 PTA1/L CD24 PTA2/L CD25 PTA3/L CD26 PTA4/L CD27/ LLWU_P15/NMI PTA5/L CD28/ CMP0OUT PTA6/L CD29/ PXBAR_IN0/LLWU_P14 PTA7/L CD30/ PXBAR_OUT0 VREFH VLL1 VLL2 VLL3 24 U1 1 2 3 4 5 6 7 8 LCD_23 LCD_24 LCD_25 LCD_26 LCD_27 LCD_28 LCD_29 LCD_30 VDDA SWD_RESET HDR 2X5 VBAT VCAP1 VCAP2 98 97 96 SWD_IO SWD_CLK VDD1 VDD2 C12 0. 1UF 2 4 6 8 10 VLL1 VL L2 VLL3 VDDA 100 99 J1 1 3 5 7 9 VDD VCAP1 VCAP2 31 MC U Ki netis M VDD1 VDD2 SWD C ON NECTOR 10 62 34 Appendix A R21 23.7K VPWR = 1.2 35V x [ 1 + R23/R24 ] (3.5956 V) 1% resisto rs R24=23.7k, R23=4 5.3k Figure A-1. Schematic diagram 01_MCU A ut om ot i ve , I ndu st ria l & M ul ti m a rk e t S ol ut i ons G ro up SAR_VDDA L21 1uH VPWR 6501 William Cannon Dr v i e West Austin, TX 78735-8598 2 C29 1uF C30 1uF C31 1uF This document cont ains infor mation p roprietary to Frees cale and sha l no t be used for engineering de sign , procur ement or man ufact ure in whole or in part without t he expres s wr ti ten permission of Fre escale. ICAP Classificat o i n: FCP: ____ Designer: Lukas Vaculik Drawing Title: Drawn by : Lukas Vaculik Page Title: Approve d: Pavel Lajsner Size C Document Number Date: Thursday, December 05, 201 3 FIUO: X PUBI: ____ 3PM ET-KM34Z128 0 1 _ MC U Rev A SCH-27826 PDF: SPF-27 826 Sheet 2 of 4 L1 L2 L2 L3 R201 220K J 201 CON TB 2 VDD R2 03 1 00K L1 R204 100K D201 BAV99LT1 DNP Current inputs R206 1k R207 47 2 3 TP231 TP2 01 R233 22 SAR_AD0 SAR_ AD0 SDADP0 1 1 2 1 R202 220 K L3 VREF/2 L1 VDD Voltage inputs R205 1k DNP C201 0.01 UF J231 CON TB 2 R231 4. 7 C231 0.0 47UF 1 2 2 RV201 2 0S0 271 R232 4. 7 DNP C232 0.0 47UF R234 22 R211 220K J 211 CON TB 2 R2 13 1 00K L2 R214 100K D211 BAV99LT1 DNP R216 1k R217 47 2 3 TP2 11 TP241 SAR_AD1 R243 22 SAR_ AD1 SDADP1 1 1 2 1 R212 220 K VREF/2 VDD SDADM0 TP232 R215 1k DNP C211 0.01 UF J241 CON TB 2 2 RV211 2 0S0 271 R241 4. 7 DNP L3 R2 23 1 00K R224 100K D221 BAV99LT1 2 3 C242 0.0 1UF R244 22 SDADM1 TP242 R226 1k R227 47 TP251 TP2 21 R253 22 SAR_AD2 SAR_ AD2 SDADP2 1 1 2 1 R222 220 K R242 4. 7 VREF/2 VDD R221 220K J 221 CON TB 2 C241 0.0 1UF 1 2 DNP R225 1k DNP RV221 2 0S0 271 J251 CON TB 2 C221 0.01 UF R251 4. 7 C251 0.0 1UF 1 2 2 R252 4. 7 DNP C252 0.0 1UF R254 22 SDADM2 TP252 Zero crossing TP261 R264 22 SAR_AD 0 SDADP3 R27 1 10 K J261 CON TB 2 CMP0 _P0 R261 4. 7 1 2 C271 1000p F R262 4. 7 DNP SAR_AD 1 C261 0.0 1UF C262 0.0 1UF R265 22 R272 10K SDADM3 CMP0 _P1 TP262 C272 1000p F R273 10K CMP0 _P5 C273 1000p F Vref/2 VPWR VREF 5 SAR_AD 2 R281 10K 3 1 R282 10K - U281 V+ LMV321 4 + V- C281 0.1UF Automotive, Industrial & Multimarket Solutions Group 6501 William Cannon Driv e West Aust in, TX7873 5-859 8 VREF/ 2 Th s i docu ment cont ains inf ormation prop rietar y to Frees cale and sh all not be u sed f or enginee ring de sign, pr ocure ment or man ufa cture in whole o r in p art with out t he e xpress written permission of Fr eescale. 2 Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. VDD C2 82 0 .1UF 35 Figure A-2. Schematic diagram 02_ANALOG ICAPClas sifica tion: FCP: ____ Designer : Lukas Vac ulik Drawing Tit e l : Drawn by : Lukas Vac ulik Pag e Title: Appr ov ed: Pav el La s j ner Size C Document Numb er Date: Thur sday , Dec embe r 05, 2013 FIUO: X PUBI: ____ 3P ME T-K M34Z128 02_Analog Re v A SCH- 27826 PDF: SPF- 27826 Sheet 3 of 4 VDD VPWR VPWR I2C1 _SCL I2C1 _SCL I2C1 _SDA I 2C1_SDA R313 0 2 VDD A A IR interface D351 WP7 104LSRD C A R342 390 D352 WP7 104LSRD C A kVAr h_LED J301 C3 01 2 .2UF D301 MMSD414 8T1G D302 MMSD41 48T1G C R306 470 1 3 5 7 9 2 4 6 8 10 R343 1.0K R321 10.0K USER_L ED D303 MMSD41 48T1G A HSMS- C170 UART3 _RXD_IR R322 1.0K 1 C 1 D35 3 C VPWR HDR_2X5 4 R341 390 k Wh _LED A 2 Q3 21 OP506B 2 C321 2200pF U303 SFH610 6-4 UART3 _TXD_IR 3 VPWR LCD_0 LCD_1 LCD_2 LCD_3 LCD_4 LCD_5 LCD_6 LCD_7 LCD_8 LCD_9 LCD_10 LCD_11 LCD_12 LCD_13 LCD_14 LCD_15 LCD_16 LCD_17 LCD_18 LCD_19 LCD_20 LCD_21 J35 0 1 3 5 7 9 11 13 15 17 19 RF_RST UART1_RTS UART1_CTS RF_I O 2 4 6 8 10 12 14 16 18 20 Tampers conection and switch LCD RF MC1323x-IPB Connector C351 0.1UF UART1_TXD UART1_RXD I 2C1_SDA I 2C1_SCL RF_CTRL CON_2X1 0 P opulate J350 on the bot tom laye r b elow LCD accord ingly to the siz e o f the MC 1322X-I PB board . Magnetic Field Tamper sensor 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 R361 1.0M DS300 LK- LCD-REV2 S3/ S7/ S15 /S16 S1/ S4/ S8/ S12 S5/ S9/ S11 /S13 S2/ S6/ S10 /S14 15D/15 E/1 5F/1 5A RMS/ 15C/15G/ 15B S35 /S1 8/S17/S19 10D/10 E/1 0F/1 0A P4/ 10C/10 G/ 10B 11D/11 E/1 1F/1 1A P5/ 11C/11 G/ 11B 12D/12 E/1 2F/1 2A P6/ 12C/12 G/ 12B 13D/13 E/1 3F/1 3A P7/ 13C/13 G/ 13B 14D/14 E/1 4F/1 4A T1/14 C/14G/14 B 1D/1E/1F/1A T2/1C/ 1G/1B S20 /S2 1/S22/S23 S27 /S2 4/S25/S26 2D/2E/2F/2A COM4 COM3 COM2 COM1 S31/S39/ S30/ S28 S3 2/9C/9 G/9B 9 D/9E/9F/9A S3 3/8C/8 G/8B 8 D/8E/8F/8A S3 4/7C/7 G/7B 7 D/7E/7F/7A S37/S38/ S39/ S40 L3/ L2/L1/ S36 P3/6C/6 G/6B 6 D/6E/6F/6A P2/5C/5 G/5B 5 D/5E/5F/5A T4/4C/4 G/4B 4 D/4E/4F/4A P1/3C/3 G/3B 3 D/3E/3F/3A T3/2C/2 G/2B 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 LCD_43 LCD_42 LCD_41 LCD_40 LCD_39 LCD_38 LCD_37 LCD_36 LCD_35 LCD_34 LCD_33 LCD_32 LCD_31 LCD_30 LCD_29 LCD_28 LCD_27 LCD_26 LCD_25 LCD_24 LCD_23 LCD_22 VDD R371 220K R362 10K TAMPER0 1 2 C361 220 0pF VDD J 361 CON TB 2 R3 72 1 0K USER_BTN DNP 1 4 D32 1 TSAL4400 CON TB 2 DNP 2 1 J302 SW371 TL3 301AF160QG R363 1.0M VDD C371 0. 1UF R364 10K TAMPER1 C362 220 0pF 1 2 J 362 CON TB 2 3 2 1 VPWR R323 680 A 2 C R307 390 PULSE_OUT DNP 4kB I2C EEPROM 2 C383 0.1UF C384 0.1UF VDDI O VDD C382 0. 1UF U38 1 SCL SDA NC INT1 7 6 I 2C1_SCL I 2C1_SDA 9 GND2 C381 1. 0UF GND1 3 CAP_A CAP_R 5 1 4 8 VDD 10 Freescale Semiconductor, Inc. Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 SFH610 6-4 U302 3 UART3 _RXD_RS2 32 UART3_TXD_ IR 4 R305 4.7K R304 1.0K LED outputs UART3_RXD_I R UART3_TXD_ RS232 R314 0 DNP UART3_TXD 3 1 VPWR UART3_RXD_RS232 R312 0 DNP UART3_RXD U301 SFH610 6-4 C UART3 _TXD_RS232 R302 390 R311 0 USART selector RS232 and Pulse output 4 36 VDD C385 0.1UF 1 2 3 4 U3 91 A0 VCC A1 WP A2 SCL GND SDA AT24C32D 8 7 6 5 VDD I 2C1_SCL I 2C1_SDA Automotive, Industrial & Multimarket Solutions Group 6501 William Cannon Drive West Au stin, TX7873 5-8598 C3 91 0 .1UF This doc ument cont ains inf ormation p ropriet ary to Fre escale and sh all not be used f or en gineering design, procur emen t or manu fac ture in wh ole or in par t wit hout the express wr itten permis sion of Freesc ale. ICAP Classif c i ation: MAG3110 Figure A-3. Schematic diagram 03_DIGITAL FCP: _ ___ Designer : Lukas Va culik Drawing Title: Drawn by : Lukas Va culik Page Title: Ap prov ed: Pa vel L ajsner Size C Docume nt Number Date: Thursda y, Decemb er 05 , 2013 FIUO: X PUBI : ____ 3P ME T- KM34Z128 03_Digital Rev A SCH- 27826 PDF: SPF-27 826 She et 4 of 4 Board layout Appendix B Board layout Figure B-1. Top side view Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 37 Board layout Figure B-2. Bottom side view Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 38 Freescale Semiconductor, Inc. Bill of materials Appendix C Bill of materials Table C-1. provides the Bill of Material report. Table C-1. BOM report Part Reference Quantity Value Description Manufacturer Part Number BT20 1 BATTERY BATTERY HOLDER CR2032 3V ROHS COMPLIANT C1,C2,C3,C4,C5,C6,C7,C8 ,C9,C10,C11,C12,C13,C28 1,C282,C371 16 0.1UF CAP CER 0.1UF 25V 10% X7R 0805 SMEC MCCC104K2NRTF C17,C18 2 18PF CAP CER 18PF 100V 5% C0G 0805 KEMET C0805C180J1GACTU C20,C21,C22,C23,C24,C2 5 6 10UF CAP CER 10UF 16V 10% X5R 0805 AVX 0805YD106KAT2A C26,C27,C28,C29,C30,C3 1 6 1uF CAP CER 1UF 50V 10% X7R 0805 SMEC MCCE105K2NRTF C90,C91 2 4.7uF CAP ALEL 4.7uF 400V 20% -- SMT C92 1 0.1uF CAP CER 0.10UF 50V 5% X7R 0805 SMEC MCCE104J2NRTF C93 1 22uF CAP CER 22UF 16V 10% X5R 0805 TDK C2012X5R1C226K C94 1 100UF CAP CER 100UF 6.3V 20% X5R 1206 Murata GRM31CR60J107ME39L C201,C211,C221,C241,C2 42,C251,C252,C261,C262 9 0.01UF CAP CER 0.01UF 100V 5% X7R 0805 KEMET C0805C103J1RACTU C231,C232 2 0.047UF CAP CER 0.047UF 50V 5% X7R 0805 KEMET C0805C473J5RAC C271,C272,C273 3 1000pF CAP CER 1000pF 1000V 10% X7R 0805 Kemet C0805C102KDRACTU C301 1 2.2UF CAP CER 2.2UF 10V 10% X5R 0805 AVX C321,C361,C362 3 2200pF CAP CER 2200PF 25V 10% X7R CC0805 C351,C382,C383,C384,C3 85,C391 6 0.1UF CAP CER 0.10UF 25V 10% X7R 0603 KEMET C0603C104K3RAC C381 1 1.0UF CAP CER 1.0UF 10V 10% X7R 0805 SMEC MCCB105K2NRTF DS300 1 LK-LCD-REV2 D20,D301,D302,D303 4 MMSD4148T1G DIODE SW 100V SOD-123 D21 1 BAT54CLT1 DIODE SCH DUAL CC 200MA 30V SOT23 ON BAT54CLT1G SEMICONDUCTOR D90,D91,D92,D94 4 MRA4007T3G DIODE PWR RECT 1A 1000V SMT 403D-02 ON MRA4007T3G SEMICONDUCTOR D95 1 ES1JL DIODE RECT 1A 600V SMT TAIWAN ES1JL SEMICONDUCTOR RENATA BATTERIES SMTU2032-LF NIC COMPONENTS NACV4R7M400V10x10.8TR13F CORP 0805ZD225KAT2A VENKEL COMPANY C0805X7R250-222KNE LCD 3-PHASE POWER AR-ELEKTRONIK SRL LK-LCD-REV2 METER ON MMSD4148T1G SEMICONDUCTOR Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 39 Bill of materials Table C-1. BOM report (continued) Part Reference Quantity Value Description Manufacturer Part Number D201,D211,D221 3 BAV99LT1 DIODE DUAL SW 215MA 70V SOT23 D321 1 TSAL4400 LED IR SGL 100MA TH D351,D352 2 WP7104LSRD LED RED SGL 30mA TH Kingbright D353 1 HSMS-C170 LED HER SGL 2.1V 20MA 0805 AVAGO TECHNOLOGIES JP1,JP2,JP3,JP4,JP5,JP6 6 HDR 1X1 HDR 1X1 TH -- 330H SN 115L SAMTEC TSW-101-23-T-S J1 1 HDR 2X5 HDR 2X5 SMT 1.27MM CTR 175H AU SAMTEC FTS-105-01-F-DV-P-TR J20,J21,J22 3 HDR_1X2 HDR 1X2 SMT 100MIL SP 380H AU SAMTEC TSM-102-01-SM-SV-P-TR J201,J211,J221,J231,J241, J251,J261,J302,J361,J362 10 CON TB 2 J301 1 HDR_2X5 HDR 2X5 SMT 100MIL CTR 380H AU SAMTEC TSM-105-01-S-DV-P-TR J350 1 CON_2X10 CON 2X10 SKT SMT 100MIL CTR 390H AU SAMTEC SSW-110-22-F-D-VS-N L20,L21 2 1uH IND CHIP 1UH@10MHZ 220MA 25% TDK MLZ2012A1R0PT L90,L91 2 1500uH IND PWR 1500UH@100KHZ 130MA 20% SMT Coilcraft LPS6235-155ML Q321 1 OP506B TRAN PHOTO NPN 250mA 30V TH RV201,RV211,RV221 3 20S0271 RES VARISTOR 275VRMS 10% 4.5kA 151J TH epcos B72220S0271K101 R1,R3,R4,R7,R8,R9,R10 7 4.7K RES MF 4.70K 1/10W 1% 0805 SMEC RC73L2A4701FTF R2 1 820 RES MF 820 OHM 1/8W 5% 0805 BOURNS R5,R311,R313 3 0 RES MF ZERO OHM 1/8W -- 0805 YAGEO AMERICA RC0805JR-070RL R6,R312,R314 3 0 RES MF ZERO OHM 1/8W -- 0805 YAGEO AMERICA RC0805JR-070RL R20 1 45.3K RES MF 45.3K 1/8W 1% 0805 BOURNS R21 1 23.7K RES MF 23.7K 1/10W 1% 0603 KOA SPEER R90,R91,R92 3 8.2 RES MF 8.2 OHM 2W 10% AXL WELWYN COMPONENTS LIMITED R93 1 2.0K RES MF 2.00K 1/10W 1% 0805 SPC TECHNOLOGY MC0805WAF2001T5E-TR R94 1 3.0K RES MF 3.00K 1/10W 1% 0805 SPC TECHNOLOGY MC0805WAF3001T5E-TR ON BAV99LT1G SEMICONDUCTOR VISHAY TSAL4400 INTERTECHNOLOGY WP7104LSRD HSMS-C170 CON 1X2 TB TH 200MIL PHOENIX CONTACT 1711725 SP 709H - 197L OPTEK OP506B TECHNOLOGY INC CR0805-JW-821ELF CR0805-FX-4532ELF RK73H1JTTD2372F EMC2-8R2K Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 40 Freescale Semiconductor, Inc. Bill of materials Table C-1. BOM report (continued) Part Reference Quantity Value Description R96 1 1.6K RES TF 1.6K 1/8W 5% 0805 R201,R202,R211,R212, R221,R222 6 220K RES MF 220K 1/4W 1% 50ppm MELF0204 WELWYN COMPONENTS LIMITED WRM0204C-220KFI R203,R204,R213,R214, R223,R224 6 100K RES MF 100K 1/4W 1% MELF0204 WELWYN COMPONENTS LIMITED WRM0204C-100KFI R205,R215,R225 3 1k RES MF 1K 200V 0.1% 15PPM MELF0204 WELWYN COMPONENTS LIMITED WRM0204Y-1KBI R206,R216,R226 3 1k RES MF 1K 200V 0.1% 15PPM MELF0204 WELWYN COMPONENTS LIMITED WRM0204Y-1KBI R207,R217,R227 3 47 RES MF 47 OHM 1/8W 1% 0805 YAGEO AMERICA 232273464709L R231,R232,R241,R242, R251,R252,R261,R262 8 4.7 RES MF 4.7 OHM 1/4W VISHAY MMA02040C4708FB300 1% MELF0204 INTERTECHNOLOGY R233,R234,R243,R244, R253,R254,R264,R265 8 22 RES MF 22 OHM 1/8W 1% 0805 R271,R272,R273,R281, R282,R362,R364,R372 8 10K RES MF 10K 1/8W 5% 0805 R302,R307 2 390 RES MF 390 OHM 1/8W 5% 0805 BOURNS CR0805-JW-391ELF R304,R322,R343 3 1.0K RES MF 1.00K 1/8W 1% 0805 KOA SPEER RK73H2ATTD1001F R305 1 4.7K RES MF 4.70K 1/8W 1% 0805 BOURNS CR0805-FX-4701ELF R306 1 470 RES MF 470 OHM 1/8W 0.5% 0805 KOA SPEER RK73H2ATTD4700D R321 1 10.0K RES MF 10.0K 1/8W 1% 0805 VENKEL COMPANY CR0805-8W-1002FT R323 1 680 RES MF 680 OHM 1/8W 5% 0805 VENKEL COMPANY CR0805-8W-681JT R341,R342 2 390 RES MF 390 OHM 1/10W SPC TECHNOLOGY MC0805WAF3900T5E-TR 1% 0805 R361,R363 2 1.0M RES MF 1.0M 1/8W 5% 0805 BOURNS R371 1 220K RES TF 220K 1/8W 5% 0805 PANASONIC ERJ6GEYJ224V SW371 1 E SWITCH TL6700AF160QG TP1,TP2,TP3,TP4,TP5, TP6,TP7,TP8,TP201, TP211,TP221,TP231, TP232,TP241,TP242, TP251,TP252,TP261, TP262 19 TL6700AF160QG SW SPST PB 50mA 12V SMT 70 MIL TEST PAD 70MIL ROUND SMT; NO PART TO ORDER Manufacturer Part Number VENKEL COMPANY CR08058W162JT YAGEO AMERICA RC0805FR-0722RL VENKEL COMPANY CR0805-8W-103JT CR0805-JW-105ELF — — Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 Freescale Semiconductor, Inc. 41 Bill of materials Table C-1. BOM report (continued) Part Reference Quantity Value Description Manufacturer Part Number U1 1 PKM34Z128CLL5 IC MCU FLASH 128K 16K 50MHZ 1.71-3.6V LQFP100 U20 1 SPX3819M5-L IC VREG LDO ADJ 500MA 2.5-16V SOT23-5 Exar U90 1 LNK302DN IC VREG LINKSWITCH 65MA/80MA 85–265VAC/700V S0-8C POWER INTEGRATIONS U281 1 LMV321 IC LIN OPAMP 130UA 2.7-5.5V SOT23-5 U301,U302,U303 3 SFH6106-4 IC OPTOCOUPLER 100MA 70V SMD U381 1 MAG3110 IC 3-AXIS DIGITAL MAGNETOMETER 1.95-3.6V DFN10 U391 1 AT24C32D IC MEM EEPROM 4096X8 1MHZ 1.8-5.5V SOIC8 ATMEL AT24C32D-SSHM-B Y1 1 32.768 KHz XTAL 32.768KHZ PAR 20PPM -- SMT Citizen CMR200T32.768KDZF-UT BT20 1 BATTERY BATTERY HOLDER CR2032 3V ROHS COMPLIANT FREESCALE PKM34Z128CLL5 SEMICONDUCTOR SPX3819M5-L LNK302DN NATIONAL LMV321M5NOPB SEMICONDUCTOR VISHAY SFH6106-4 INTERTECHNOLOGY FREESCALE MAG3110FC SEMICONDUCTOR RENATA BATTERIES SMTU2032-LF Kinetis-M Three-Phase Power Meter Design Reference Manual, DRM147, Rev. 0 42 Freescale Semiconductor, Inc. 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